Advanced Poly-Packaging Ti-1000 User manual

1-800-754-4403
U.S.A.
1331 Emmitt Rd. • Akron, OH. 44306
330-785-4000 • Fax [phone]
www.advancedpoly.com • [e-mail]
U.K.
Advanced Poly-Packaging-UK, Ltd.
Over Causeway, Over, Glouchester GL2 8DB
44 1452 332400 • Fax [phone]
www.advancedpoly.com • [e-mail]
®

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Ti-1000 Inline
Thermal Transfer Printer
______________________________________________________________________________
Operation Guide, Ver 1
Setup and Operation guide

Warranty & Disclaimer
Warranty period is one year or 1,000,000 linear inches of print, whichever comes first. The
warranty commences on the date of delivery of the equipment.
APPI warrants to the Purchaser that the equipment is free from defects in workmanship or material
under normal use and service. During the warranty period, APPI agrees to repair or replace, at its
sole option, without charge to Purchaser, any defective component part of the equipment. To obtain
service, Purchaser must return the equipment or component to APPI or an authorized APPI
distributor or service representative in an adequate container for shipping. Any shipping charges,
insurance, or other fees must be paid by Purchaser and all risk for the equipment shall remain with
Purchaser until such time as APPI takes receipt of the equipment. Upon receipt, APPI, the
authorized distributor or service representative will promptly will promptly repair or replace the
defective component and then return the equipment or component to Purchaser, shipping charges,
insurance and additional fees prepaid. APPI may use reconditioned or like new parts or units, at its
sole option, when repairing any component or equipment. Repaired products shall carry the same
amount of outstanding warranty as from original purchase. Any claim under the warranty must
include dated proof of delivery. In any event, APPI’s liability for defective components is limited
to repairing or replacing the components.
This warranty is contingent upon proper use of equipment by Purchaser and does not cover:
expendable component parts such as print heads, rollers, bushings, or if damage is due to accident,
unusual physical, electrical or mechanical stress, neglect, misuse, failure of electrical power,
improper environmental conditions, transportation, tampering with or altering of the equipment,
packaging of corrosive or contaminating products or other products damaging to components, and
equipment or components not owned or in the possession of the original Purchaser.
APPI will not be liable for loss of production, profits, lost savings, special, incidental, consequental,
indirect or other similar dmages arising from beach of warranty, advised of the possibility of such
damages or for any claim brought against the Purchaser by another party.
This warranty allocates risks of equipment failure between Purchaser and APPI. APPI’s pricing
reflects this allocation of risk and the limitations of liabilities contained in this warranty. This
warranty set forth above is in lieu of all other express warranties, whether oral or written. The
agents, employees, distributors and dealers of APPI are not authorized to make modifications to this
warranty, or additional warranties binding on APPI. Accordingly, additional statements such as
dealer advertising or presentations, whether oral or written, do not constitute warranties by APPI
and should not be relied upon.

Contents
__________________________________________________________________
Chapter 1, Introduction
1.1 Welcome
1.2 Overview
1.3 Capabilities and Performance
1.4 Options and Accessories
1.5 Printer Specifications
1.6 Electronics Specifications
1.7 Print Specifications
1.8 Ribbon Specifications
1.9 System Integration
1.10 Using This Manual - Topographical Conventions
Chapter 2, Getting Started
2.1 Installation Procedures
2.2 Assembly Instructions
2.3 Air & Power Hookup
2.4 Auxiliary Port Connection
2.5 Remote Panel Connection
2.6 Main Power
2.7 Film/Bag Threading
2.8 Printer Ribbon Threading
2.9 Print Registration and Alignment
2.10 Notes on Adjustments of the Ti-1000

Contents
__________________________________________________________________
Chapter 3, Parts Identification
3.1 Message Display
3.2 Display Panel Identification
3.3 Electronics Panel - Major Components & Right Side
3.4 Back Panel - Parts Identification
3.5 Printer Major Components (Top View)
3.6 Printer Components Identification - Print Head Assembly Upper & Lower
3.7 Power Supply Components Identification
3.8 CPU PC Board Component Identification
3.9 Interface Board
3.10 Ribbon Roll Shaft Detail
3.11 Drive Assembly Detail
3.12 Harness Description and Location
3.13 Recommended Spare Parts List - 203 DPI Printer
3.14 Recommended Spare Parts List - 305 DPI Printer
Chapter 4, Operation
4.1 Sequence of Operation
4.2 Test Printing
4.3 Signalling Between Bagger & Printer to Print In-Line
4.4 Diusplay Operation
4.5 Label Counters
4.6 Clearing the Printer Memory
4.7 Parameter Settings
4.8 In-Line Bar Code Verifier Setup & Operation

Contents
_________________________________________________________________
Chapter 5, Machine Adjustments & Replacement
of Components
5.1 Threading Adjustment (Bag Web Guides)
5.2 Constant Film / Bag Tension
5.3 Bagger Film Tracking / Alignment
5.4 Print Head Replacement
5.5 Note on Print Quality
5.6 Print Head Course Alignment
5.7 Print Head Fine Adjustment
5.8 Lever Arm Adjustment
5.9 Head Down Sensor
5.10 Inserting the Optional Flash Memory Card
Chapter 6, Preventative Maintenance &
Trouble-Shooting
6.1 Key Maintenance Data
6.2 Recommended Tools / Accessories
6.3 Equipment Cleaning / Cleanliness of Materials
6.4 Print Head Cleaning
6.5 Roller Cleaning
6.6 Preventative Maintenance Checklist
6.7 Scheduled Maintenance Chart
6.8 Preventative Maintenance (PM) Performed (Additional)
6.9 Maintenance Record (Other Maintenance Performed)
Chapter 7, Trouble-Shooting
7.1 Trouble-Shooting Checklist
7.2 Trouble-Shooting - Error Messages

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Identification Checklist & Registration Information:
Item: APPI Inspector: Purchaser's Inspection:
Serial Number
PCB S/N
IF Board S/N
PS Board S/N
4" / 5" / 8" Head
Optional Equipment:
______ Verifiers
______ Software Version
______ PrintPad
______ Scanners
______ Laptop Computer
Model, S/N:
Other: 
REGISTRATION INFORMATION:
This section must be completed and returned to Advance Poly Packaging, Inc. to register the RAP
1400 for Warranty Protection. (See warranty contained in this manual for specific warranty
information)
Company Name & Address Contact Name(s) / Title(s) / Phone Number
________________________________
________________________________
________________________________

_______________________________________________
_______________________________________________
_______________________________________________

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Operation Guide
__________________________________________
Chapter 1, Introduction
Welcome
Overview
Capabilities and Performance
Options and Accessories
Printer Specifications
Electronics Specifications
Print Specifications
Ribbon Specifications
System Integration
Using This Manual - Typographical Conentions

1.1 Welcome
Thank you for selecting the TI-1000 IN-LINE THERMAL TRANSFER PRINTERTM, manufactured by
ADVANCED POLY-PACKAGING, INC. We know you will be satisfied with its durability,
functionality and performance.
1.2 Overview
Through increased production and decreased inventory, thermal transfer printing can save thousands by
lowering packaging costs.
Print directly onto the bag or film surface and eliminate non-printed label stock and preprinted label
inventories. Increase production and reduce labor codes; stop hand applying costly paper labels to your
product.
1.3 Capabilities & Performance
GRAPHIC CAPABILITY
Print with a selection of 60 types of characters (fonts), 20 types of bar codes (including European
specification bar codes), lines, boxes, and graphic images. Print labels up to 4 inches wide (or 5" wide
with optional 305 dpi, 5" head) and up to 35 inches long!
HIGH QUALITY PRINT
Printing at speeds of 10 inches per second with high resolution 203 dots per inch (or optional 305 dpi
head) is now possible, allowing you to take advantage of the fastest autobagger (T-1000 Advanced Poly-
BaggerTM) automatic L-Sealer of FFS machine. The high dot density produces clear, clean print required
for perfect scannability of bar codes and readability of finely printed text.
DURABILITY
Rugged, durable construction provides protection in heavy industrial manufacturing environments.
Floating-edge head revolution allows for extended print head life. Since the print head heat element is
positioned at the edge of the print head, print quality is significantly improved without the need to adjust
the head for varying media thickness.
HIGH SYSTEM PERFORMANCE
High throughput can be obtained with "on-the-fly" formatting. And realize faster downloading of large
labels of scanned input PCG or PCX files due to an onboard 16-bit CPU.

1.4 Options & Accessories
THERMAL TRANSFER RIBBON
We stock thermal transfer ribbon in all available widths. Colors are also available upon request.
SPARE PARTS KITS
Level 1 Spare Parts Kit (P/N T-TISP10) includes a cleaning and lubrication kit, a spare print head and
other items required for normal wear and preventable maintenance. Level 2 Spare Part Kit (P/N T-
TISP20) includes items in the Level 1 Kit plus items which may fail not due to normal wear.
WIDER, HIGH RESOLUTION PRINT HEAD
Upgrade the TI-1000 with the optional 305 dpi, 5" wide print head with no loss of production.
BAR CODE VERIFIERS
In-line verifiers guarantees that every bar code is readable and/or the correct code. Programmable to halt
printing or signal the operator for bad reads, no reads and also marginal read bar codes. Hand-held
verifiers allow for periodic reading of orders for quality control of the finished product.
PC'S (LAPTOP)
IBM or other major brand laptop computers specifically designed for manufacturing environments with
the latest performance specifications at exceptional values. All major computers come pre-loaded with
the latest Windows version and label software so you simply plug in and download.
PRINTER CONTROLLERS
Instead of having a PC on the shop floor, we offer a rugged controller which single purpose and ease of
use minimize training of shop floor personnel. No software training required.
SCANNERS
Hand-held "trigger" scanners offer scanned input versus operator input to eliminate operator error.
Simply scan the bar code of the last printed sample and all of the information is down- loaded
automatically! Also verifies the readability of bar codes.
LABEL SOFTWARE
We offer several software packages which allows you to select the best solution to fit your process.
Integrate to virtually any database files and avoid having to re-input your data. Software available for
DOS, Windows 3.11 or Windows 95.

MEMORY MODULE
Increase downloading performance, extend buffer up to 512K and store larger files into memory.
FLASH MEMORY CARD
Save logos, writable characters and print formats to this 1MB card.
HIGH SPEED INTERFACE CARD
Increase performance of down-loading of data from databases (address lists, part numbers, incrementing
serial files, etc.) on a first-in, first-out command transfer method.
1.5 Printer Specifications
Weight: 60 Lbs.
Dimensions: 18" wide x 18" deep x 14" high
Supply voltage: AC 100V-120V +10%, -15%, 60HZ
Power consumption: 190W/2.2A max
Stand by: 22A, 15W
Operating temperature: 41 degrees F- 104 degrees F
Relative humidity: 25%-85% RH, no condensation
Print head: 203.2 dots per inch or optional 305 dots per inch
Print method: Thermal transfer
Print speeds: 3 inch/sec, 6 inch/sec, 10 inch/sec
Optional head: 3, 6, 8 inches/sec
Maximum print width: 4.09 inches or optional 5 inches
Dispensive modes: Batch (continuous, tear-off)
Message display: 16 characters + 1 line
NOTE: Specifications may change without notice.
1.6 Electronics Specifications
1) CPU PD70236AGD-16-588
2) Memory
a) Program: EP-ROM 128KB
b) Character generator: Mask ROM 512KB
c) Backup: EE-PROM 128 Bytes
d) Image buffer + Work D-RAM 512KB (max 2MB-Option)
3) Interface (RS-232C) Straight through Cable
a) Communication mode: Full-duplex
b) Transmission speed: 2400, 4800, 9600, 19200 BPS
c) Synchronization: start-stop synchronization
d) Transmission parameter:
*Parity: None, EVEN, ODD
* Start bit: 1-bit
* Stop bit: 1-bit or 2-bit
* Word length: 7-bit or 8-bit

1.7 Print Specifications
TYPES OF BAR CODE
1) UPC-A, UPC-A + 2 digits, UPC-A + 5 digits
2) UPC-E, UPC-E + 2 digits, UPC-E + 5 digits
3) EAN128
4) EAN 8, EAN 8 + 2 digits, EAN 8 + 5 digits, EAN 13, EAN 13 + 2 digits EAN 13 + 5 digits
5) JAN 8, JAN 13
6) NW-7
7) CODE 39 (standard/full ASCII)
8) CODE 93, CODE 128 (auto code switch with/without)
9) ITF
10) MSI
TYPES OF CHARACTERS
1) Times Roman medium (12,15 point)
2) Times Roman bold (15, 18, 21 pt)
3) Times Roman italic (18 pt)
4) Helvetica medium (9, 15, 18 pt)
5) Helvetica bold (18, 21 pt)
6) Helvetic italic (18 pt)
7) Presentation bold (27)
8) Letter Gothic med (14.3 pt)
9) Prestige Elite med (10.5 pt)
10) Prestige Elite bold (15 pt)
11) Courier med (15 pt)
12) Courier bold (18 pt)
13) OCR-A,B (12 pt)
14) Outline font (Helvetica bold)
15) Writable characters (40 types) (224 char./types)
MAGNIFICATION OF BAR CODE
UPC/EAN/JAN/CODE 93/128 Up to 4 modules can be automatically calculated using 1-module width
designation (1to 15 dots).
Dots/Module
Bar Code 2 3 4 5 6 7 8
UPC-A/E Min Module Width
(mm)
EAN 8/13 Magnification (times)
JAN 8/13
0.25
0.75
0.38
1.14
0.50
1.51
0.63
1.91
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CODE 93 Min Module Width (mm) 0.25 0.38 0.5O 0.63 0.75 0.88 1.OO
EAN 128 Min Module Width (mm)
CODE 128 0.25 0.38 0.5O 0.63 0.75 0.88 1.OO
Dots/Module
Bar Code 9 10 11 12 13 14 15
UPC-A/E Min Module Width
(mm) EAN 8/13 Magnification
(times)
JAN 8/13
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CODE 93 Min Module width (mm) 1.13 1.25 1.38 1.5O 1.63 1.75 1.88
EAN 128 Min Module Width (mm)
CODE 128 1.13 1.25 1.38 1.5O 1.63 1.75 1.88
NW-7/CODE 39/ ITF/MSI The width of narrow bars, wide bars and spaces can be optionally changes
in a range of 1 to 99 dots.
MAGNIFICATION OF CHARACTERS
1) Regular font: 0.5 - 9.5 times (magnified by 0.5 times in each direction)
2) Outline font: 2.0 - 85.0mm (magnified by 0.1mm in each direction)
CHARACTER ROTATION
0,90,120,270 degrees
TYPE OF LINE
1) Horizontal
2) Vertical
3) Slant line
4) Square
MAGNIFICATION OF LINES
2 to 8 dots in units of .1mm
1.8 Ribbon Specifications

ITEM DESCRIPTION
Shape Spool type
Width 68 - 112mm
Max. length 600 m
Max. OD O90mm
Back treatment Coated
Core material Cardboard
Leader tape Polyester film (Opaque), 300 + 5mm long
End tape Polyester Film (Opaque), 250 + 5mm long
Winding method The ink side is outside ribbon winding
Do not store ribbon for longer than the manufacturers recommended shelf life. Store the media on its
flat end, not on the curved sides. Store partially used ribbon rolls in plastic bags: Unprotected or dirty
ribbon causes extra abrasion on the print head and will shorten print head life.
Avoid exposure to direct sunlight, high temperatures, high humidity, dust or gas.
1.9 System Integration
The Ti-1000 is specifically designed to perfectly integrate to the T-1000 Advanced Poly Bagger TM and
other Advanced Poly-Packaging baggers, but will integrate to packaging equipment (vertical or
horizontal FFS machines, other brand baggers and other packaging equipment. Please contact APPI
technicians and sales staff for assistance in integrating the Ti-1000 printer to your equipment.
FREE CONSULTATION AND PRODUCT EVALUATION
We invite you to discuss your packaging requirements and our free product packaging analysis.
1.10 Using this manual - Typographical Conventions
The following manual conventions are frequently used to assist in understanding important information,
alerting the operator of potentially dangerous or damaging practices, and the normal functions of the Ti-
1000 Inline Thermal Transfer Printer TM.
Text Normal text
<RESET> Used to show KEY FUNCTIONS / KEYS
Italics Used for emphasis
BOLDFACE Used to identify heading names
! Used to identify important information
CAUTION: Warning messages: To avoid physical harm, damage to
equipment or damage to the product. Be sure to read these
messages carefully.

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Operation Guide
________________________________________
Chapter 2, Getting Started
______________________________________________________________________________
Installation Procedures
Assembly Instructions
Air & Power Hookup
Auxiliary Port Connection
Remote Panel Connection
Main Power
Film/Bag Threading
Printer Ribbon Threading
Print Registration and Alignment
Notes on Adjustments of the Ti-1000

Chapter 2 Getting Started
This chapter describes in detail procedures to receive and setup the Ti-1000 Inline Thermal Transfer
Printer, mounting, environmental, air and power requirements.
Additionally, this chapter describes how to turn on power to the Ti-1000 and properly thread bags
through the machine.
2.1 Installation Procedures
The Ti-1000 is transported as a single unit in a carton designed to protect the machine during shipment
or mounted to a bagger (if sold as an option to a bagger). It is shipped completely assembled except for
a few items which are easily attached during installation with final adjustment. Refer to inspections,
operation, packing and crating checklists in Appendix A for options included, accessories included and
location of components shipped.
Unpacking / Inspection
After removing the printer from the container, inspect the unit for damage. If the printer is mounted to a
bagger, remove the outer wrapping and ensure the cables are plugged in securely.
Operating Environment
The Ti-1000 should be placed in an area free of excessive heat, moisture, dirt and dust. Operating room
temperature should range from 41 to 104 degrees Fahrenheit at 25 to 85% relative humidity with no
condensation.
Power Requirements
Provisions must be made for 110-120V +10%, 60 Hz line current with ground.
Power consumption for the Ti-1000 is 190W / 2.2 A max.
CAUTION: A qualified electrician should ensure that the Ti-1000 power outlet is properly grounded,
voltages are as required and amperage capacity is sufficient.
Note: APPI recommends a dedicated 20 Amp circuit for the T-1000 w/ Ti-1000 Printer option.
Air Requirements
At least .5 CFM free air is required, regulated to 40 PSI.
Note: Air should be dry and oil-free.
2.2 Assembly Instructions
Choose an operating location, considering traffic flow, availability of film and printer supplies, supply
of product to be packaged, take-a-way of finished packages and placement of auxiliary infeed and
outfeed equipment.